WO2013153413A1

WO2013153413A1 - Modular system for producing prototypes and moulds

Info

Publication number: WO2013153413A1
Application number: PCT/IB2012/000740
Authority: WO
Inventors: Gergely LIPOCZI
Original assignee: Lipoczi Gergely
Priority date: 2012-04-12
Filing date: 2012-04-12
Publication date: 2013-10-17

Abstract

The subject of the invention is a modular system for producing prototypes and moulds, which is applicable for quickly producing moulds, plugs and prototypes based on small modular blocks. The system according to the invention consists of small modular prismatic blocks placed and fixed in organizing frame side by side, and the surface of the prismatic blocks establish the outer surface for the mould or plug or prototype. It is characterised by that, the blocks (4) placed in the organizing frame (2) together constitute a block set (1) corresponding to a mould, in which prism shaped blocks (4) are used with various shapes at their end surfaces (15) and at their side surfaces (16), preferably with square or rectangular base, where the end surfaces (15) and in given case the side surfaces (16) of the blocks (4) provide parts or surface units of the outer surface (7) of the mould, plug or prototype, and the prismatic blocks (4) are installed in the organizing fame (2) in a manner, that the end surfaces (15) and in given case the side surfaces (16) of the bocks (4) constitute the outer surface (7) of the mould, plug or prototype without the need for subsequent machining.

Description

Modular system for producing prototypes and moulds

The subject of the invention is a modular system for producing prototypes and moulds, which is applicable for quickly producing moulds, plugs and prototypes based on small modular blocks.

Plastic processing and injection moulding technologies generally need the application of expensive production moulds made of metal. The making of production moulds is a rather expensive and time consuming process, which hinders the fast production of products, delays the placing of the product on the market, as well as the return of invested resources. According to the present practice, the introduction of a new product is started with designing the product with CAD methods based on functional, structural and designing aspects, the final results of which is a 3D CAD model. The second step is the manufacture of a plug or prototype, as a result of which the pilot lot can be manufactured. This process is rather lengthy, may take several months, and the machining with CNC machines is very expensive.

In order to manufacture production moulds faster and with less expenses the industry started to develop various solutions. One of the approach in the development efforts includes the preparation of the shape of the profile to be produced by specific assembling of prefabricated standard components.

According to the state of the art the US 2010 295229 patent publication makes known a tooling system with array of height adjustable elements. The tooling system having a number of elements arranged in an array, which elements define a contoured surface, or a section of a contoured surface. The tooling system also including means for mounting an element to a support rail which extends across the array, which means allows adjustment of the height of the element with respect to other elements of the array, and extends through the support rail into a space defined below the support rail. A supporting element formed from a suitable resistant material and including accommodation means for the means for mounting, is located in the space below the support rail and is sized so that it substantially vertically fills the space between the support rail and a base on which the tooling system is located.

The US 2009 020936 patent publication makes known a reconfigurable workpiece support. The tooling system comprises a plurality of elongate elements each having an upper surface, said elements being arranged in an array to present said upper surfaces for machining by cutting tool means; support means for supporting said elements, each said element being supported on said support means for axial movement between upper and lower positions relative to the other elements in the array thereby to enable adjustment of the vertical position of said element surface; and clamping means for clamping the array of elements in a closed position in which the elements contact one another for enabling the free ends of the elements to be machined to produce a desired surface contour. A method of tooling using such a tooling system comprises storing existing data representing the contour of the surface of each element including the z values of the surface at any given x,y coordinate point relative to a datum; storing new data representing a desired contour for the surface of each element position in the array including the z values of the surface at said any given x,y coordinate point relative to said datum; comparing said new data for a first, selected element position with the existing data for a first element in said selected element position; and adjusting the height of said first element to adjust said z values of said existing data at said any given x,y coordinate point to values at least equal to said z values; of said new data at said any given x,y coordinate point.

The US 2004 145105 patent publication makes known a workpiece support. The tooling system comprises a plurality of elements arranged in an array, each element being moveable longitudinally relative to the other elements in the array and a first end, the system further comprising means to adjust the relative longitudinal positions of the elements such that the free ends of the elements define approximately a desired surface contour and means for retaining the elements in their adjusted positions.

The deficiencies of the solutions known and applied according to the state of art includes the need for further removal of material from the surface approximately assembled from prismatic blocks, e.g. by milling or grinding. The final surface cannot be established merely by placing the block side by side. The mould assembled in this manner is unique, its components cannot be used again fully. The machining means an extra process, which needs lots of work and expenditure.

For the development of the solution according to this invention our aim was to create a system, with the help of which various production moulds, plugs any prototypes can be made easily. The additional objective was to ensure, that the applied blocks could be used, applied later for establishing further plugs.

During the development of the solution according to the invention we recognised, if the plug is assembled from blocks having a square cross section and tops with various shapes, which are placed in an organizing frame arranged according to the shape to be established, in which frame the blocks are fastened, and the surface produced this way corresponds to the surface of the mould or the prototype, the set aim can be achieved.

The invention is a modular system for producing prototypes and moulds, which is applicable for quickly producing moulds, plugs and prototypes, which consists of small modular prismatic blocks placed and fixed in organizing frame side by side, and the surface of the prismatic blocks establish the outer surface for the mould or plug or prototype. It is characterised by that, the blocks placed in the organizing frame together constitute a block set corresponding to a mould, in which prism shaped blocks are used with various shapes at their end surfaces and at their side surfaces, preferably with square or rectangular base, where the end surfaces and in given case the side surfaces of the blocks provide parts or surface units of the outer surface of the mould, plug or prototype, and the prismatic blocks are installed in the organizing fame in a manner, that the end surfaces and in given case the side surfaces of the bocks constitute the outer surface of the mould, plug or prototype without the need for subsequent machining.

In a preferred realization of the system according to the invention the blocks are installed within the organizing frame between organizing plates, and for the lateral positioning and fixing of blocks in the organizing frame, there are tightening elements preferably at all sides of the organizing frame, supported by the organizing plate, and the tightening elements installed in the organizing frame stabilize the blocks relative to one another and to the organizing frame too.

In another preferred realization of the system according to the invention there are height adjusting elements - in given case threaded rods - beneath the organizing fame for adjusting the desired height of the blocks, where the said height adjusting elements are connected partly to the bottom of the blocks and partly to the height adjusting frame situated beneath the organizing frame, in given case to the threaded drills drilled in the height adjusting frame, and that the blocks can be adjusted to the desired vertical positions one by one relative to each other according to the geometrical surface to be established with the help of the height adjusting elements.

In a further preferred realization of the system according to the invention compensating blocks are also used in addition to the blocks in the block set for establishing the desired outer surface of the plug, and that the blocks have shaped surfaces at their sides formed by means of CNC milling machine.

In a further preferred realization of the system according to the invention milled square cuts are established in the side of blocks for the purpose of stabilizing the blocks relative to one another and to the organizing frame, and that in given case positioning wedges are attached to the square cuts.

In a further preferred realization of the system according to the invention the material of the blocks is hard, wear resistant and dimensionally stable substance, in given case metal or metal alloy, for example steel, aluminium, filled resin or hard plastic foam, in given case PUR or PVC, or artificial wood, or wood.

In a further preferred realization of the system according to the invention the end of the blocks is a planar final surface, or shaped with chamfer in angle a, or with a rounding with radius r, or are shaped with round corner or nick.

In a further preferred realization of the system according to the invention one side surface of the blocks is formed with an inward leaning draft having angle β.

In a further preferred realization of the system according to the invention the rectangular body of the blocks and compensating blocks is in given case a prism having base area 50x50 mm, or 50x100 mm, or 100x100 mm, or 50x200 mm, or 100x200 mm, or 200x200 mm. In a further preferred realization of the system according to the invention the organizing frame may have various sizes, preferably matched to the dimensions of the plug or mould to be manufactured, each overall dimension being 20-20 mm larger that that of the plug or mould.

In a further preferred realization of the system according to the invention the typical size of the organizing frame is in given case 500x500 mm, 1000x1000 mm, 500x1000 mm, 500x2000 mm, 1000x2000 mm, or 2000x2000 mm.

In a further preferred realization of the system according to the invention the possible engineering solutions of the height adjusting element include threaded rod, or ball screw, or trapezoidal thread screw, or it has a hydraulic solution, in given case hydraulic cylinder, or is has pneumatic solution, in given case a pneumatic cylinder, or it is a linear actuator working with magnetism.

In a further preferred realization of the system according to the invention the blocks (4) in the system in given case are blocks with rounded edges, blocks providing draft, blocks with flange, blocks featuring countersink, blocks containing positioning studs, blocks providing cavity for hinge or lock, undercut blocks, blocks forming an arc, drafted blocks forming an arc, blocks forming an angle, blocks with ornamental parts, text, numbers or date, blocks providing cavity for standard electrical sockets, blocks providing cavity for standard lamps, cameras, block providing cavity for standard hydraulic, pneumatics sockets, blocks providing cavity for connection points of standard mounting brackets, bolts.

In a further preferred realization of the system according to the invention in the system within a type range, the blocks may have various sizes, for example in the typical range of rounded edge blocks it is possible to have blocks providing rounded edges with various radii too, and blocks providing chamfered edges with various angles and sizes.

In a further preferred realization of the system according to the invention, the sequence of the production process is as follows:

- selecting suitable blocks based on the geometry to be achieved,

- checking the overall dimensions of the geometry,

- selecting production frame and height adjusting elements with suitable dimensions,

- inserting the blocks are placed into the organizing frame, the positioning wedges into the square cuts of the blocks,

- connecting the height adjusting elements to the blocks,

- adjusting and checking the required height of the blocks,

- activating the tightening elements,

- checking the lengthwise and crosswise dimensions with CMM machine, and further measurements are made as required by the customer,

- inserting additional compensating blocks as necessary,

- treating the blocks with form-release agent and by waxing,

- preparing the negative mould, the production mould with the desired method, the first layer is applied, and the operation of the vacuum pump is started if necessary,

- measuring the ready prototype, plug or mould, preparing the measuring report, The solution according to the invention is furthermore set forth by the following figures:

Fig. 1 shows an actual embodiment of the block set established on the basis of the system according to the invention in upper perspective view.

Fig. 2 shows the block set shown in Fig. 1 in bottom perspective view.

Fig. 3 shows the block set shown in Fig. 1 in lateral view.

Fig. 4 shows the top view of the block set shown in Fig. 1.

Fig. 5 shows another actual embodiment of the block set established according to the invention in perspective view.

Fig. 6 is a side view of the blocks installed in the organising frame shown in Fig. 5. Fig. 7 is a top view of the block installed in the organising fame shown in Fig. 5.

Fig 8 is a perspective view of a possible embodiment of blocks of the system according to the invention.

Fig 9 is the perspective view of another possible embodiment of block of the system according to the invention.

Fig. 10 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 11 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 12 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 13 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 14 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 15 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 16 is a perspective view of yet another possible embodiment of block of the system according to the invention.

Fig. 17 is a perspective view of yet another possible embodiment of block of the block set according to the invention.

Fig. 18 is a perspective view of yet another possible embodiment of block of the block set according to the invention.

Fig. 1 shows an actual embodiment of the block set established on the basis of the system according to the invention in upper perspective view. The components that can be seen in the figure include organizing frame 2 of the block set 1, with the tightening elements 6 mounted on its side, as well as the height adjusting frame 3. The Fig shows, that in the organizing frame 2 the blocks 4 are fitted to each other and to the organising plate 8 located in the organising frame in a space filling manner. The external surface 7 is composed of the differently shaped individual surfaces of the blocks 4, which are placed next to one another in an appropriate arrangement. It can be seen in the figure, that there are blocks with one chamfer 11, there are blocks with double chamfer at the corner part, and there are two blocks 4 with countersink 9. Fig. 2 shows the block set shown in Fig. 1 in bottom perspective view. The components that can be seen in the figure include organizing frame 2 of the block set 1, with the tightening elements 6 mounted on its side, the height adjusting frame 3 as well as blocks

4. There are drills 10 in the bottom of the height adjustment frame 3, through which the height adjusting elements 5 are passed and screwed into the blocks 4, which are in given case threaded rods.

Fig. 3 shows the block set shown in Fig. 1 in lateral view. The components that can be seen in the figure include block set 1, the blocks 4 placed in the organising frame 2, as well as the height adjusting frame 3. Also, the figure shows the height adjusting elements 5, which are passed through the bottom of the height adjusting frame 3 and screwed into the blocks 4. Additionally, one can see in the figure the organising plates 8 that are installed in the organising frame 2, together with the tightening elements 6 mounted on the outer surface of the organising frame 2. One of the blocks 4 establishing the outer surface 7 has one chamfer 11, and there are blocks 4 at the corned parts that have double chamfer 11.

Fig. 4 shows the top view of the block set shown in Fig. 1. In the figure can be seen the organizing frame 2 of the blocks set 1 with the lightening elements 6 on it's side, as well as the organising plates 8 installed in the organising frame 2. In the organizing frame 2 the blocks 4 are fitted to one another and to the organising plate 8 in a space filling manner. It can be seen in the figure, that among the blocks 4 forming the outer surface 7, there are blocks with one chamfer 11, and at the corner part there are blocks 4 with double chamfer 11, and there are two blocks 4 with countersink 9.

Fig. 5 shows another actual embodiment of the block set established according to the invention in perspective view. In the figure can be seen the height adjusting frame 3, as well as the organizing plates 8 placed on the inner surface of the organizing frame 2, and blocks 4 that are placed in it in space filling manner. The height adjusting elements

5, that are screwed into the blocks 4, are passed through the bottom of height adjusting frame 3. Also, one can see in the figure an outer surface 7, which is established by the appropriately shaped surfaces of blocks 4, which are placed next to one another with appropriate arrangement. In the figure can be seen that among the blocks 4 establishing the outer surface 7 there are blocks 4 with rounded edge 12, and also with round corner 13.

Fig. 6 is a side view of the blocks installed in the organising frame shown in Fig. 5. In the figure can be seen the height adjustment frame 3, the organising plates 8 mounted on the inner side of the organizing frame 2, blocks 4 that are placed in it in space filling manner, as well as the height adjusting elements 5 that are passed through the bottom of height adjusting frame 3 and screwed into the blocks 4. Also, the figure shows the outer surface 7 which is established by the varying surfaces of blocks 4 placed next to one another in appropriate arrangement. There are blocks 4 with rounded edges 12 among the blocks 4 that establish the outer surface 7.

Fig. 7 is a top view of the block 4 installed in the organising fame 2 shown in Fig. 5. In the figure can be seen the figure include the organising plates 8 mounted on the inner side of the organizing frame 2, and blocks 4 that are placed in it in a space filling manner. It is well visible in the figure, that the blocks 4 are fitted in a closed manner to one another, as well as to the organising plates 8 mounted on the inner side of the organising frame 2.

Fig 8 is a perspective view of a possible embodiment of blocks 4 of the system according to the invention. The figure shows a block 4 with standard design, which block 4 in given case has a shape of a rectangular prism, its top is cut horizontally, and this constitutes the final surface 15. The longer edge of the rectangular block 4 has a hight H measurement, with width Wl and W2 measurements, while the length S is the measurement of the height adjusting element 5 outside the block 4 screwed into the block 4.

Fig 9 is the perspective view of another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4 having a shape of rectangular prism, in which in given case a countersink 9 is established at the top part of block 4, having a diameter of D and depth of "h", and this constitutes the final surface 15.

Fig. 10 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4 having a shape of a rectangular prism, in which case one side of the rectangular solid is chamfered with angle β along its side surface 16. The plug surface established by this chamfer allows the establishment of a mould, the draft of which corresponds to the expectations of the plastic processing technologies. Preferably, angle β is > 2°.

Fig. 11 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4 which has a chamfer 11 established along one of its side with an angel of a. In this case the a angle is 1° < a < 89°.

Fig. 12 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4, in which one side of the rectangular body is slightly chamfered, shaped with a chamfer 11. It can be seen in the figure well, that a part having a length of L2 is cut off from the top of the block 4 with an angle of a, and a part having a length of LI is cut off from the width W2. In this case the a angle is 1° < a < 89°.

Fig. 13 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4 which is designed as a rectangular body with chamfer 11 along its two sides.

Fig. 14 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figures shows a block 4, which is established as a rectangular body with rounding 12 along one of its edges with a radius of "r".

Fig. 15 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows a block 4 with rounding 12 having a radius of "r", where the size of radius "r" is less than width W2 of block 4 having the shape of a rectangular body.

Fig. 16 is a perspective view of yet another possible embodiment of block 4 of the system according to the invention. The figure shows the block 4 designed as a rectangular prism, which is slightly chamfered with an angle of β along the one of the side surfaces 16, and having a rounding 12 with radius "r". In this case the dimensions of radius "r" is identical to the width W2 of the blocks 4 shaped as a rectangular body. Preferably, the angle β is > 2°.

Fig. 17 is a perspective view of yet another possible embodiment of block 4 of the block set according to the invention. The figure shows an round corner block 4 having two rounded edges 12, and one arched block with round corner 13.

Fig. 18 is a perspective view of yet another possible embodiment of block 4 of the block set according to the invention. The figure shows two blocks 4 designed as rectangular body having round 12 and nick 14.

The possible advantageous actual embodiments of the solution according to the invention are as follows:

In its preferred embodiment the solution according to the inventions is a system, which is suitable for quickly producing moulds, plugs and prototype from small blocks 4. In case of the basic embodiment of the system the plugs and moulds usually made from a single piece are replaced with blocks 4 containing identical elements. In more complicated cases of mould with lose inserts or split shape, the elements may consists of several pieces too. The base shape of the blocks 4 is preferably is a square or rectangle, or triangle and hexagon, or any polygon, which can fill the plane in itself or in combination with other polygons, for example an octagon with a square.

The blocks 4 may be made of any hard material, such as metal, plastic or plastic foam, or even wood. The blocks 4 may be prefabricated in various sizes, characteristically having rectangular bodies with base area: 50x50 mm, 50x100 mm, 100x100 mm, 50x200 mm, 100x200 mm or 200x200. In certain cases, it might be necessary to use compensating blocks with the same sizes. The width Wl and W2 of these blocks are adjustable. In certain cases, the blocks 4 may have shaped surfaces at a number of sides prepared with CNC milling machine, where the said shapes ensure fitting and guiding the surfaces relatively to each other in a precise manner.

The blocks 4 are placed in an organizing frame 2 so that they provide the required geometry of the plug, prototype of mould as a result of the adjacent milled surfaces, therefore, the organizing frames 2 may have different sizes too depending on the size of the plug or mould to be established. The dimensions of the organizing fame 2 shall be larger by 20-20 mm relative to the maximum overall dimensions. The characteristic dimensions of the organizing frame 2 are 500x500 mm, 1000x1000 mm, 500x1000 mm, 500x2000 mm, 1000x2000 mm, or 2000x2000 mm. Fasteners are installed in the organizing frame, which stabilize the blocks 4 relative to one another and relative to the frame as well. For establishing the suitable surface, it is necessary to adjust the height of the blocks in various ways.

In case of a preferred embodiment, in the system among the blocks 4 within the respective type ranges there are blocks 4 provide edges, surface, corners, and compensating too.

So called compensating blocks may be used in order to compensate any lengthwise or crosswise deviations relative to the planned values. The dimensions of these blocks may differ from those of the blocks belonging to the given typical range in lengthwise and crosswise directions, although they have the properties of the blocks of the typical range.

When the beneficial preferred embodiment of the system according to the invention is used, then the process of manufacturing is as follows:

1. Selecting suitable blocks 4 based on the geometry to be achieved.

2. Checking the overall dimensions of the geometry.

3. Selecting production frame and height adjusting elements 5 with suitable dimensions.

4. Inserting the blocks 4 are placed into the organizing frame 2, the positioning wedges into the square cuts of the blocks 4.

5. Connecting the height adjusting elements 5 to the blocks 4.

6. Adjusting and checking the required height of the blocks 4.

7. Activating the tightening elements 6.

8. Checking the lengthwise and crosswise dimensions with CMM machine, and further measurements are made as required by the customer.

9. Inserting additional compensating blocks 4 as necessary.

10. Treating the blocks 4 with form-release agent and by waxing.

11. Preparing the negative mould, the production mould with the desired method, the first layer is applied, and the operation of the vacuum pump is started if necessary.

12. Measuring the ready prototype, plug or mould, preparing the measuring report.

In an actual preferred solution according to the invention, the blocks 4 having hard resistant surfaces, are placed in the first step from the top in the organising frame 2, so that the blocks 4 touch one another as well as the side wall of the organising frame 2. The threaded rods 5 are preferably screwed into the bottom of the blocks 4 in threaded holes 10.

The height adjustment frame 3 situated beneath the organizing fame 2 is established from horizontal metal frame or from a system of metal rails. In given case in these rails are placed threaded drills 10. Height adjusting elements 5, in given case threaded rods, are fitted in the bottom of the blocks 4 through the holes 10 drilled in the height adjusting frame 3. The height adjusting elements 5, which are in given case threaded rods, can be turned clockwise and counter clockwise for adjusting the height of the blocks 4 relative to one another and to the organizing frame 2, and the spatial height of the blocks can be fixed by tightening the height adjusting elements 5. The blocks 4 are to be kept in appropriate vertical position range relative to the height adjusting frame 3 situated beneath the organizing frame 2 with the help of the height adjusting elements 5.

Various engineering solutions are available for establishing the height adjustment element 5, for example:

- threaded rod

- ball screw

- trapezoidal thread screw

- hydraulic solution, cylinder

- pneumatic solution, cylinder

- linear actuator

- magnetic solution

The stability of blocks 4 relative to one an other and to the organizing frame 2 in given case can be ensured with the help of the square cut in the side of blocks 4 and the positioning wedges attached to the square cuts.

Detachable joints are used to fasten the blocks 4 to one another and to the side surfaces 16 of the organizing frame 2, which are connected to the holes, square cuts and wedge ways in the side walls of the blocks 4 and organizing frame 2.

The tops and side surfaces of blocks 4 are prepared in advance with milling or other machining operations (planing, grinding, polishing, etc.). The upper and side surfaces of blocks 4 can be established in any geometrical form, and they can have undercuts too. The surfaces of blocks 4 placed side by side in the organizing frame 2 provides a continuous surface for the prototype, plug or mould to be manufactured. The blocks 4 fitted to one another and adjusted to the appropriate heights jointly provide a mould assembly. The ready mould assembly is treated with form-release agents as necessary prior to use. Upon completion of the operations of tool making and prototype manufacture, the mould assembly can be dismantled and the blocks can be used again after thorough cleaning in different configurations.

In the system according to the invention, the blocks 4 are sorted into a number of type ranges according but not limited to the informative list below:

- blocks with rounded edges

- blocks with chamfered edges

- blocks providing draft

- blocks providing flanges

- blocks providing countersink

- blocks containing positioning studs

- blocks providing cavity for a hinge or lock

- blocks providing undercut

- blocks forming and arc

- crafted blocks forming an arc

- blocks forming an angle

- blocks with ornamental parts

- blocks with text, dates - blocks providing cavity for standard electronic sockets

- blocks providing cavity for standard lamp an camera sockets

- blocks providing cavity for standard pneumatic, hydraulic sockets

- blocks providing cavity for connection points of standard mounting brackets, bolts

Within a typical range the blocks 4 can have different dimensions, for instance, in the typical range of blocks with rounded edges, it is possible to have block 4 with edges rounded with various radii, or it is possible to have chamfered blocks 4 with various angles and dimensions of the chamfers.

The advantage of the solution according to the invention is that the system provides services to industrial companies in relation to tool making, preparation of prototype, supplemented with services related to the engineering, designing and structural calculations. With the use of this new technology the throughput time, which is usually is a couple of weeks or months in the tool making practice, can be reduced to several days, with one third/quarter of the market price. With the help of the solution according to the invention it is possible to reduce the time necessary for producing plugs, prototypes and mould, as well as the manufacture of pilot lot, relative to the presently used tool making practice, to several days, or even to a couple of hours in case of simple products, and at the same time the costs are reduced to a third or fourth. The customer is able to optimize the designing cost also, because the efforts required for assembling the required geometry from the pieces of a ready system is much less, as the designer is able to work on the basis of ready catalogue. The system is extremely flexible thanks to the large number of elements, and of course further modules can also be added according to the customer requirements.

List of references:

1 - block set

2 - organising frame

3 -height adjusting frame

4 - block

5 - height adjusting element

6 - tightening element

7 - outer surface

8 - organising plate

9 - countersink

10 - drill

11 - chamfer

12 - round

13 - round corner

14 - nick

15 - final surface

16 - side surface

H - height (block)

Wl - width (block)

W2 - width (block)

S - length (height adjusting element) h - depth (countersink)

LI - length

L2 - length a - angle

β - angle

r - radius of round

Claims

CLAIMS:

1. Modular system for producing prototypes and moulds, which is applicable for quickly producing moulds, plugs and prototypes, which consists of small modular prismatic blocks placed and fixed in organizing frame side by side, and the surface of the prismatic blocks establish the outer surface for the mould or plug or prototype, characterised by that, the blocks (4) placed in the organizing frame (2) together constitute a block set (1) corresponding to a mould, in which prism shaped blocks (4) are used with various shapes at their end surfaces (15) and at their side surfaces (16), preferably with square or rectangular base, where the end surfaces (15) and in given case the side surfaces (16) of the blocks (4) provide parts or surface units of the outer surface (7) of the mould, plug or prototype, and the prismatic blocks (4) are installed in the organizing fame (2) in a manner, that the end surfaces (15) and in given case the side surfaces (16) of the bocks (4) constitute the outer surface (7) of the mould, plug or prototype without the need for subsequent machining.

2. System according to claim 1 characterised by that, the blocks (4) are installed within the organizing frame (2) between organizing plates (8), and for the lateral positioning and fixing of blocks (4) in the organizing frame (2), there are tightening elements (6) preferably at all sides of the organizing frame (2), supported by the organizing plate (8), and the tightening elements (6) installed in the organizing frame (2) stabilize the blocks

(4) relative to one another and to the organizing frame (2) too.

3. System according to claim 1 or 2 characterised by that, there are height adjusting elements (5) - in given case threaded rods - beneath the organizing fame (2) for adjusting the desired height of the blocks (4), where the said height adjusting elements

(5) are connected partly to the bottom of the blocks (4) and partly to the height adjusting frame (3) situated beneath the organizing frame (2), in given case to the threaded drills (10) drilled in the height adjusting frame (3), and that the blocks (4) can be adjusted to the desired vertical positions one by one relative to each other according to the geometrical surface to be established with the help of the height adjusting elements (5).

4. System according to any of the Claims 1 -3 characterised by that, compensating blocks are also used in addition to the blocks (4) in the block set (1) for establishing the desired outer surface (7) of the plug, and that the blocks (4) have shaped surfaces at their sides formed by means of CNC milling machine.

5. System according to any of the claims 1 - 4 characterised by that, milled square cuts are established in the side of blocks (4) for the purpose of stabilizing the blocks (4) relative to one another and to the organizing frame (2), and that in given case positioning wedges are attached to the square cuts.

6. System according to any of the claims 1 - 5 characterised by that, the material of the blocks (4) is hard, wear resistant and dimensionally stable substance, in given case metal or metal alloy, for example steel, aluminium, filled resin or hard plastic foam, in given case PUR or PVC, or artificial wood, or wood.

7. System according to any of the claims 1 - 6 characterised by that, the end of the blocks (4) is a planar final surface (15), or shaped with chamfer (11) in angle a, or with a rounding (12) with radius r, or are shaped with round corner (13) or nick (14).

8. System according to any of the claims 1 - 7 characterised by that, one side surface (16) of the blocks (4) is formed with an inward leaning draft having angle β.

9. System according to any of the claims 1 - 8 characterised by that, the rectangular body of the blocks (4) and compensating blocks is in given case a prism having base area 50x50 mm, or 50x100 mm, or 100x100 mm, or 50x200 mm, or 100x200 mm, or 200x200 mm.

10. System according to any of the claims 1 - 9 characterised by that, the organizing frame (2) may have various sizes, preferably matched to the dimensions of the plug or mould to be manufactured, each overall dimension being 20-20 mm larger that that of the plug or mould.

11. System according to any of the claims 1 - 10 characterised by that, the typical size of the organizing frame is in given case 500x500 mm, 1000x1000 mm, 500x1000 mm, 500x2000 mm, 1000x2000 mm, or 2000x2000 mm.

12. System according to any of the claims 1 - 11 characterised by that, the possible engineering solutions of the height adjusting element (5) include threaded rod, or ball screw, or trapezoidal thread screw, or it has a hydraulic solution, in given case hydraulic cylinder, or is has pneumatic solution, in given case a pneumatic cylinder, or it is a linear actuator working with magnetism.

13. System according to any of the claims 1 - 12 characterised by that, the blocks (4) in the system in given case are blocks with rounded edges, blocks providing draft, blocks with flange, blocks featuring countersink, blocks containing positioning studs, blocks providing cavity for hinge or lock, undercut blocks, blocks forming an arc, drafted blocks forming an arc, blocks forming an angle, blocks with ornamental parts, text, numbers or date, blocks providing cavity for standard electrical sockets, blocks providing cavity for standard lamps, cameras, block providing cavity for standard hydraulic, pneumatics sockets, blocks providing cavity for connection points of standard mounting brackets, bolts.

14. System according to any of the claims 1 - 13 characterised by that, in the system within a type range, the blocks (4) may have various sizes, for example in the typical range of rounded edge blocks (4) it is possible to have blocks (4) providing rounded edges with various radii too, and blocks (4) providing chamfered edges with various angles and sizes.

15. System according to any of the claims 1 - 14, characterised by that, during the advantageous preferred application of the system, the sequence of the production process is as follows:

- selecting suitable blocks (4) based on the geometry to be achieved,

- checking the overall dimensions of the geometry,

- selecting production frame and height adjusting elements (5) with suitable dimensions,

- inserting the blocks (4) are placed into the organizing frame (2), the positioning wedges into the square cuts of the blocks (4),

- connecting the height adjusting elements (5) to the blocks (4),

- adjusting and checking the required height of the blocks (4),

- activating the tightening elements (6),

- inserting additional compensating blocks (4) as necessary,

- treating the blocks (4) with form-release agent and by waxing,

- measuring the ready prototype, plug or mould, preparing the measuring report,